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Last Modified:
08-30-2021
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6.10:8.0.50
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Doc ID:
RM100000000RZU2
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Model Year Start:
2016
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Model:
Prius
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Prod Date Range:
[11/2015 - 12/2018]
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Title:
DOOR / HATCH: FRONT DOOR: DISASSEMBLY; 2016 - 2018 MY Prius [11/2015 - 12/2018]
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DISASSEMBLY
CAUTION / NOTICE / HINT
The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during front door removal/installation are shown below.
Necessary Procedure After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure
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Necessary Procedure
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Effect/Inoperative Function when Necessary Procedure not Performed
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Link
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Disconnect cable from negative auxiliary battery terminal
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Memorize steering angle neutral point
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Lane departure alert system (w/ Steering Control)
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Intelligent clearance sonar system*1
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Simple advanced parking guidance system*1
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Pre-collision system
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Initialize back door lock
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Power door lock control system
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Door window regulator sub-assembly
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Door glass
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Door glass run
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Initialize Power Window Control System
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Auto up and down function
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Jam protection function
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Catch protection function
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Remote control function
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Key-linked function
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Wireless transmitter-linked function
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Key-off operation function
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Window open warning function
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*1: When performing learning using the Techstream: Click here
HINT:
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Use the same procedure for the RH side and LH side.
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The following procedure is for the LH side.
PROCEDURE
1. PRECAUTION
CAUTION:
Be sure to read Precaution thoroughly before servicing.
Click here
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
Click here
2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG
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(a) Using a moulding remover, disengage the 3 claws to remove the front door inside handle bezel plug.
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4. REMOVE FRONT ARMREST ASSEMBLY
(a) Disengage the 3 clips and 7 claws as shown in the illustration.
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Place Hand Here
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Remove in this Direction
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(b) Disengage the guide to remove the front armrest assembly as shown in the illustration.
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Remove in this Direction
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5. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side)
(a) Disengage the 2 clips and 4 claws as shown in the illustration.
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Place Hand Here
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Remove in this Direction
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(b) Disconnect the connector to remove the multiplex network master switch assembly with front door upper armrest base panel.
6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side)
(a) Disengage the 2 clips and 4 claws as shown in the illustration.
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Place Hand Here
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Remove in this Direction
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(b) Disconnect the connector to remove the power window regulator switch assembly with front door upper armrest base panel.
7. REMOVE COURTESY LIGHT ASSEMBLY
Click here
8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY
(a) Apply protective tape to the front door panel as shown in the illustration.
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Protective Tape
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(c) Disengage the 2 clips.
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(d) Using a clip remover, disengage the 10 clips.
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(e) While pulling out the front door trim board sub-assembly, insert a hand between the front door trim board sub-assembly and front door panel up to the area where the claws are engaged.
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(f) While pulling down the part of the front door inner glass weatherstrip shown in the illustration, pull out the front door trim board sub-assembly to disengage the 2 claws.
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Place Hand Here
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(g) Using a clip remover, disengage the clip.
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(i) Pull out the front door trim board sub-assembly to disengage the guide from the front door panel.
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(j) Lift the front door trim board sub-assembly to separate the front door trim board sub-assembly with the front door inner glass weatherstrip from the front door panel.
NOTICE:
To prevent damage to the guide, lift the front door trim board sub-assembly with the guide disengaged.
(k) Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly to remove the front door trim board sub-assembly as shown in the illustration.
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*1
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Front Door Inside Locking Cable Assembly
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*2
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Front Door Lock Remote Control Cable Assembly
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Remove in this Direction
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9. REMOVE FRONT DOOR VENT SEAL
(a) Remove the front door vent seal from the front door inner glass weatherstrip as shown in the illustration.
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Remove in this Direction
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10. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP
(a) Slide the front door inner glass weatherstrip to remove it from the front door trim board sub-assembly as shown in the illustration.
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Remove in this Direction
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11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
(a) Disengage the 2 claws to remove the front door inside handle sub-assembly.
12. REMOVE FRONT DOOR PANEL PROTECTOR
Click here
13. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY
Click here
14. REMOVE FRONT DOOR NO. 3 SERVICE HOLE COVER
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(a) Remove the front door No. 3 service hole cover.
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15. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
Click here
16. REMOVE FRONT DOOR SERVICE HOLE COVER
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(a) Turn each front door weatherstrip clip 45 degrees and remove the 3 front door weatherstrip clips as shown in the illustration.
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(b) Disengage the 4 clips to remove the front door service hole cover.
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17. REMOVE DOOR SIDE AIRBAG SENSOR
Click here
18. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
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(a) Remove the hole plug.
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(b) for Driver Side:
(1) Connect the multiplex network master switch assembly.
(c) for Front Passenger Side:
(1) Connect the power window regulator switch assembly.
(d) Connect the cable to the negative (-) auxiliary battery terminal.
(e) Turn the power switch on (IG).
(f) Move the front door glass sub-assembly so that the door glass bolts can be seen.
(g) Turn the power switch off.
(h) Disconnect the cable from the negative (-) auxiliary battery terminal.
(i) for Driver Side:
(1) Disconnect the multiplex network master switch assembly.
(j) for Front Passenger Side:
(1) Disconnect the power window regulator switch assembly.
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(k) Remove the 2 bolts.
NOTICE:
After the bolts are removed, do not allow the front door glass sub-assembly to fall.
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(l) Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
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Remove in this Direction (1)
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Remove in this Direction (2)
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NOTICE:
Do not damage the front door glass sub-assembly.
19. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY
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(a) Disengage the 2 claws to remove the front door No. 2 service hole cover.
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(b) Disconnect the connector.
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(c) Loosen the temporary bolt.
NOTICE:
Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator assembly may fall and cause damage.
(d) Remove the 5 bolts.
(e) Remove the front door window regulator assembly.
(f) Remove the temporary bolt from the front door window regulator assembly.
20. REMOVE FRONT DOOR GLASS RUN
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(a) Remove the front door glass run.
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21. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
(a) Remove the bolt.
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Remove in this Direction
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(b) Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.
22. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY
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(a) Disengage the 2 claws.
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(b) Using a screwdriver, disconnect the connector.
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(c) Disengage the 3 clamps.
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(d) Disengage the 2 claws and move the lever as shown in the illustration.
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Disengage in this Direction
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(e) Remove the front door outside handle assembly as shown in the illustration.
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Remove in this Direction
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23. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)
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(a) Remove the hole plug.
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(b) Using a T30 "TORX" socket wrench, loosen the screw and remove the front door lock cylinder assembly.
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24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
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(a) Remove the hole plug.
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(b) Using a T30 "TORX" socket wrench, loosen the screw.
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(c) Disengage the 2 guides and claw and remove the front door outside handle cover.
25. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD
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(a) Disengage the 3 claws to remove the front door front outside handle pad.
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26. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD
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(a) Disengage the 3 guides and claw to remove the front door rear outside handle pad.
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27. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY
Click here
28. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
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(a) Using a T30 "TORX" socket wrench, remove the screw.
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(b) Slide the front door outside handle frame sub-assembly to disengage the claw and remove the front door outside handle frame sub-assembly.
29. REMOVE FRONT DOOR LOCK OPEN ROD
(a) Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
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Remove in this Direction (1)
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Remove in this Direction (2)
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30. REMOVE FRONT DOOR CHECK ASSEMBLY
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(a) Remove the 3 bolts and front door check assembly.
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31. REMOVE FRONT DOOR WEATHERSTRIP
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(a) Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.
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32. REMOVE DOOR FRAME GARNISH
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(a) Disengage the 3 claws to remove the door frame garnish.
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33. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
(a) Remove the 3 bolts, screw and front door front lower frame sub-assembly.
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Bolt
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Screw
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34. REMOVE FRONT DOOR FIX WINDOW GLASS
(a) Remove the front door fix window glass with front door fix window weatherstrip as shown in the illustration.
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Remove in this Direction
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(b) Remove the front door fix window glass from the front door fix window weatherstrip.
35. REMOVE FRONT DOOR PANEL CUSHION
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(a) Disengage the 4 claws to remove the 2 front door panel cushions.
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36. REMOVE FRONT DOOR DUST PROOF SEAL
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(a) Disengage the 3 claws to remove the 3 front door dust proof seals.
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37. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY
Click here
38. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING
Click here
39. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING
Click here
40. REMOVE FRONT DOOR REAR OUTSIDE STRIPE (w/ Black Out Tape)
Click here
41. REMOVE FRONT DOOR STRIPE (w/ Black Out Tape)
Click here
42. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape)
Click here
43. REMOVE FRONT DOOR SCUFF PLATE
Click here
44. REMOVE COWL SIDE TRIM BOARD
Click here
45. REMOVE FRONT DOOR FRONT WINDOW FRAME MOULDING
Click here
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